Human-Readable Information vs Barcodes: Handling Scanner Failures

Human-Readable Information (HRI) Text printed near a barcode that presents encoded data in a form people can read without scanning the symbol. HRI and barcodes are complementary: barcodes provide machine-speed accuracy while HRI provides human-accessible redundancy and a verification layer when scanners or systems cannot be used.

Failures in barcode scanning happen for many reasons — poor print quality, label placement, glare from shrinkwrap, damaged symbols, or incompatible symbology. HRI exists so staff can continue operations when automation is interrupted. Understanding how HRI and barcodes interact helps fulfillment managers design resilient workflows and reduce downtime.

Common Scanning Failure Modes Where HRI Helps

• Print Defects: Smearing, low resolution, or improper contrast may make a barcode unreadable but leave the HRI intact.
• Physical Damage: Torn or scuffed labels may remove part of a barcode; readable text nearby may still convey the required fields.
• Environmental Conditions: Condensation, dirt, or reflective packaging may foil optical scanners while HRI printed on non-reflective surfaces remains legible.

Operational Workflows That Use HRI

Fulfillment centers should plan workflows that assume barcode read failures will occur occasionally. Practical workflows include:

• Scan-First, Human-Fallback: Primary workflows rely on scanning. When the WMS returns a read error, the operator manually types the HRI into a quick-entry screen or a handheld terminal.
• Visual Verification Step: Critical shipments include a manual cross-check of HRI against the pick list or packing slip before sealing the carton.
• Exception Handling: Create tickets in the WMS for damaged labels that include HRI text so supervisors can authorize manual overrides or reprint labels.

Formatting For Fast Manual Entry

Design HRI layout with manual entry in mind. Avoid long, ambiguous strings without separators. For multi-field labels, include clear separators and human identifiers so data can be transcribed quickly and correctly.

• Segmentation: Break multi-field strings into labeled chunks (GTIN:, Lot:, Exp:).
• Consistent Order: Keep the same field order across labels so operators don't need to search for fields.
• Shortcuts: If your WMS supports it, allow partial HRI entry (e.g., last 6 digits of GTIN) to reduce keystrokes.

When Manual Entry Is Risky

Manual entry increases the chance of human error. Use HRI as a fallback, not a replacement for scanning, in high-volume flows or where traceability is critical (e.g., pharmaceuticals). Where possible, pair manual entry with verification — double-entry, checksum validation, or on-screen prompts that flag unlikely values (expired dates or mismatched GTIN formats).

Training And Performance Measurement

Include HRI procedures in operator onboarding and quality metrics. Measure the frequency of HRI-driven manual entries, time-per-manual-entry, and downstream error rates. If manual entries remain high, investigate root causes: poor print quality, damaged labels, or inadequate scanner hardware.

Practical Example

At a 3PL handling refrigerated consumer goods, seasonal humidity caused shrink labels to wrinkle and many mobile scanners returned read errors. The center’s SOP required operators to read the HRI beneath the GS1-128 label and enter GTIN and lot into the handheld. The warehouse also logged damaged-label incidents so the labelling supplier adjusted print parameters. The combination of immediate HRI fallback plus longer-term corrective action cut receiving delays by 60% during peak season.

In short, the Human-Readable Information (HRI) printed near a barcode is the practical backup when scanners fail: it supports exception handling, reduces delays, and — when formatted and integrated into procedures properly — limits the risk of manual-entry errors in fulfillment operations.